Eaton Transmission CL-550 Service Manual

Service Manual

Fuller Mid Range Transmissions TRSM0197

October 2007

For parts or service call us

Pro Gear & Transmission, Inc.

1 (877) 776-4600

(407) 872-1901

parts@eprogear.com

906 W. Gore St.

Orlando, FL 32805

Caution -

Before towing the vehicle, be sure to lift the rear wheels off the

ground or disconnect the driveline to avoid damage to the

transmission during towing.

FOREWARD

This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the CLARK® Transmission. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the transmission, its principle of operation, troubleshooting and adjustments, it is urged that the service person study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of components parts is required, only Clark-approved parts as listed in the applicable parts manual should be used. Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment. The Clark Equipment Company does not warrant repair or replacement parts, nor failures resulting from the use thereof, which are not supplied by or approved by the Clark Equipment Company.

IMPORTANT: Always furnish the Distributor with the transmission serial and model number when ordering parts.

CL550 SERIES TRANSMISSION

The CL550 is a 5-speed forward, 1-speed reverse transmission of advanced design offering you the most efficient torque capacity-to-weight ratio of any 5-speed transmission in its torque range. Two basic ratios are available as shown in the table below. The CL551 ratio is designed for use in trucks equipped with a 3 or 4-speed auxiliary transmission and the CL557 ration is designed for use with trucks equipped with a 2-speed rear axle.

MODELS

Speed

Fifth Direct Direct Direct

Fourth 1.52:1 1.17:1 1.28

Third 2.54:1 1.99:1 2.15

Second 4.35:1 3.68:1 3.68

First 7.52:1 6.82:1 6.36

Reverse 6.27:1 5.30:1 5.30

Constant mesh in all gears, including low and reverse, is a CL550 feature as is helical gearing throughout, including low and reverse.

The Clark split-pin synchronizer is used in 2nd, 3rd 4th and 5th gears. Greater bearing capacity in the CL550 is achieved by the use of numerous needle roller bearings, and two tapered roller bearings and one large straight roller bearing at the rear of the countershaft.

Shift forks have replaceable bronze inserts. The shift pattern is of the standard progression type with all shifts having the same throw at the lever.

CL551/390V CL557/397V CL558

Page B shows a cutaway drawing of the CL550. Page C shows a cutaway drawing of the 390V.

CLARK

CL550 TRANSMISSION

CLARK

390V TRANSMISSION

THE CLARK SYNCHRONIZER

AND HOW IT WORKS FOR YOU

The Clark split-pin synchronizer prevents the clashing of the gears and increase the speed of shifting.

In a conventional transmission which does not have synchronizers the absence of gear clashing is dependent entirely on the skill of the truck driver. By double-clutching and split second timing of engine speeds with the gear shifting movement, a driver can synchronize the speeds of the engaging gears and thereby prevent the damage to gears by clashing when a fast shift. The splint-pin sychronzier performs the same function with or without the “double-clutching” operating even though the driver does not accurately time his gear shifting movements. It also mechanically prevents the driver from completing the shift to the point of gear engagement until the engaging gears have reached the same or synchronous speeds. This is known as the blocking action of the synchronizer and it is this action that makes the operation of shifting a transmission having synchronizers different from one which does not have synchronizers.

Upon shifting gears in these synchronized transmissions the first part of the gear shift lever movement brings the blockers into contact. The blockers momentarily prevent further movement of the shift lever and the pressure exerted by the driver to complete the movement, is transferred by the blockers to the synchronizer providing the force necessary to synchronize the gears being engaged. When the engaging gears have reached the same speed, the blockers automatically disengage, permitting the gear shift lever movement to be completed. Therefore, to properly shift a synchronized transmission a steady and continuous pressure must be applied by the driver to the shift lever until the shift is completed. Under normal conditions this action is instantaneous.

Sometimes difficulty is experienced in shifting a synchronizer when the vehicle is standing still. This is caused by the fact that the disengagement of the blockers requires relative rotation and with the vehicle at rest and with the engine clutch released, there may be at times, no relative rotation of the engaging gears. Under these conditions, the same continuous pressure should be applied to the shift lever and at the same time, the clutch should be engaged slightly. This will give sufficient rotation to unblock the synchronizer and allow the shift to be completed without difficulty.

RECOMMENDED LUBRICANTS FOR CLARK

MANUALLY SHIFTED TRANSMISSIONS

*Mil-L-2105C Extreme Pressure Lubricant (or API classification GL-5) of the SAE viscosity recommended in the chart at the right is preferred. All lubricants should be backed by the reputation of a well-know supplier. It is important to specify EP lubricants of the MIL-L-2105C type only, or of a API classification GL-5.

*Do not use extreme pressure lubricants other than MIL-L-2105C or of a API classification GL-5.

Many EP lubricants contain highly-active chemical compounds that have been formulated to perform satisfactorily in specific types of applications. Severe corrosion, residual deposits, and inadequate lubrication may result from improper application. Use of EP lubricants other that MIL-L-2105C or of a API classification GL-5 may result in failure and/or impaired operation.

DRAINING ECONOMY - The object in draining the transmission oil periodically is to eliminate possible bearing surface abrasion and attendant wear. Minute particles of metal, the product of normal wear in service, are deposited in and circulate with the transmission oil. The oil changes chemically, due to its repeated heating and cooling, also the terrific churning it undergoes in the presence of air. It is desirable to drain out this used oil after the first 1,000 miles (1609,0 Km) of service (regardless of type of service). Subsequent drains should be

made every 24,000 miles (38616,0 Km) or six (6) months (whichever comes first) for highway service, and every 8,000 to 10,000 miles [12872,0-16090,0 Km] or six (6) months (whichever comes first) “on-off” highway and “pick-up and delivery” types of service. Do this only when the transmission is thoroughly warm.

FLUSHING - After draining, flushing is desirable. Replace the drain plug and fill the transmission to the proper level with a light flushing oil. Drive the transmission for a short period at fast idle in such a manner that the gears in the transmission are rotating without load. This washes out the old oil clinging to the interior of the gear case, covers and shifter rails. BE SURE TO DRAIN OUT ALL of the flushing oil before attempting to refill with new oil. This flushing procedure is most important after first drain.

REFILL - First, removal all dirt around the filler plug, Then refill with new oil of a grade recommended for the existing season and prevailing service. Fill to the bottom of the level testing plug positioned on the side of the transmission. DO NOT OVERFILL, as the excess quantity will serve no useful purpose. If the oil level is too high, it will cause excessive oil churning and high oil temperature and possible leakage.

INSPECTION - Oil level inspection should be made every 6,000 miles [9654,0 Km] which usually coincides with the vehicle manufacturers chassis lube procedure. Always clean around filler plug before inspection. Add sufficient oil to maintain correct level.

CLARK

CapscrewCL550-SERIES TRANSMISSION

ITEM DESCRIPTION QTY.

1 Control Cover Gasket...............................................................1

2 Lockwasher............................................................................14

3 Control Cover Screw..............................................................14

4 Control Cover Assembly ..........................................................1

5 Mainshaft Reverse Gear Bearing Spacer..................................1

6 Mainshaft Reverse Gear Roller Bearing..................................48

7 Mainshaft Reverse Gear Bearing Spacer..................................1

8 Mainshaft Reverse Gear Roller Bearing..................................48

9 Mainshaft Reverse Gear...........................................................1

10 1st & Reverse Shift Hub Sleeve...............................................1

11 Shift Hub Sleeve Retainer Ring................................................1

12 1st & Reverse Shift Hub ..........................................................1

13 Mainshaft 1st Gear Bearing Spacer..........................................1

14 Mainshaft 1st Gear Roller Bearing .........................................44

15 Mainshaft 1st Gear Bearing Spacer..........................................1

16 Mainshaft 1st Gear Roller Bearing .........................................44

17 Mainshaft 1st Gear...................................................................1

18 Split Washer Retainer Ring......................................................1

19 Mainshaft Rear Bearing Cone...................................................1

20 Ball...........................................................................................1

21 Split Washer Retainer Ring......................................................1

22 Mainshaft 2nd & Reverse Gear Split Washer ...........................2

23 Mainshaft 2nd Gear..................................................................1

24 Mainshaft 2nd Gear Bearing Spacer.........................................1

25 Mainshaft 2nd Gear Roller Bearing ........................................48

26 Mainshaft 2nd Gear Bearing Spacer.........................................1

27 Mainshaft 2nd Gear Roller Bearing ........................................48

28 Mainshaft.................................................................................1

29 2nd & 3rd Synchronizer Assembly ..........................................1

30 3rd Gear Synchronizer Cup......................................................1

31 Mainshaft 3rd Gear Roller Bearing**.....................................48

32 Mainshaft 3rd Gear Bearing Spacer ** ....................................1

33 Mainshaft 3rd Gear Roller Bearing**.....................................48

34 Mainshaft 3rd Gear Bearing Spacer** .....................................1

35 Mainshaft 3rd Gear..................................................................1

36 Ball**.......................................................................................1

37 Mainshaft 3rd Gear Locating Washer.......................................1

38 Mainshaft 3rd Gear Retainer Ring............................................1

39 Mainshaft 4th Gear Roller Bearing**.....................................34

40 Mainshaft 4th Gear Bearing Spacer**......................................1

41 Mainshaft 4th Gear Roller Bearing**.....................................34

42 Mainshaft 4th Gear ..................................................................1

43 4th & 5th Shift Hub Sleeve.......................................................1

18A - Mainshaft Rear Bearing Split Washer**................1

ITEM Description QTY.

44 4th & 5th Synchronizer Cup.....................................................1

45 4th & 5th Synchronizer Assembly............................................1

46 4th & 5th Synchronizer Cup.....................................................1

47 4th & 5th Shift Hub Bearing ....................................................1

48 4th & 5th Shift Hub Bearing Race............................................1

49 Name Plate Screw....................................................................2

50 Name Plate...............................................................................1

51 Countershaft Gear Retainer Ring .............................................1

52 Countershaft Drive Gear...........................................................1

53 Countershaft 4th Gear..............................................................1

54 Countershaft Gear Key.............................................................2

55 Countershaft ...........................................................................1

56 Oil Baffle ..................................................................................1

57 Countershaft Rear Bearing.......................................................1

58 Countershaft Rear Bearing Outer Retainer Ring.......................1

59 Countershaft Rear Bearing Retainer Ring ................................1

60 Countershaft Rear Bearing Cap Gasket....................................1

61 Countershaft Rear Bearing Cap................................................1

62 Lockwasher..............................................................................4

63 Rear Bearing Capscrew............................................................4

64 Mainshaft Rear Bearing Cup & Snap Ring ...............................1

65 Speedometer Drive Gear..........................................................1

66 Mainshaft Rear Bearing Cap Gasket.........................................1

67 Mainshaft Rear Bearing Cap.....................................................1

68 Lockwasher..............................................................................3

69 Mainshaft Rear Bearing Capscrew ...........................................3

70 Mainshaft Rear Bearing Cap Oil Seal........................................1

71 Mainshaft Flange Nut ...............................................................1

72 Speedometer Tube Nut.............................................................1

73 Speedometer Driven Gear........................................................1

74 Mainshaft Rear Bearing Capscrew ...........................................1

75 Lockwasher..............................................................................1

76 Reverse Idler Lockscrew..........................................................1

77 Reverse Idler Shaft Lock..........................................................1

78 Reverse Idler Shaft ..................................................................1

79 Reverse Idler Thrust Washer ...................................................1

80 Reverse Idler Gear Bearing Spacer...........................................1

81 Reverse Idler Gear Bearing ....................................................26

82 Reverse Idler Gear ..................................................................1

83 Reverse Idler Gear Bearing Spacer...........................................1

84 Reverse Idler Gear Bearing ....................................................26

85 Reverse Idler Gear Bearing Spacer...........................................1

86 Reverse Idler Thrust Washer....................................................1

87 Mainshaft Spigot Bearing Washer Retainer Ring.....................1

ITEM Description QTY.

88 Mainshaft Spigot Bearing Washer............................................1

89 Mainshaft Spigot Bearing.......................................................14

90 Main Drive Gear ......................................................................1

91 Main Drive Gear Bearing Cone.................................................1

92 Main Drive Gear Bearing Cup...................................................1

93 Main Drive Gear Bearing Shim..............................................AR

94 Main Drive Gear Bearing Cap Oil Seal......................................1

95 Main Drive Gear Bearing Cap...................................................1

96 Lockwasher..............................................................................4

97 Bearing Capscrew....................................................................4

98 P.T. O. Cover Plate Screw.........................................................6

99 P.T. O. Cover Plate....................................................................1

100 P.T. O. Cover Plate Gasket........................................................1

101 Transmission Case...................................................................1

102 Countershaft Pilot Bearing.......................................................1

103 Clutch Housing to Case Stud ...................................................2

104 Pedal Shaft Grease Fitting........................................................2

105 Pedal Shaft Bushing.................................................................1

106 Clutch Housing Cover..............................................................1

107 Clutch Housing Cover Screw Lockwasher................................2

108 Clutch Housing Cover Screw ...................................................2

109 Bushing....................................................................................1

110 Bushing....................................................................................1

111 Clutch Housing To Case Stud Nut............................................6

112 Clutch Housing To Case Stud Lockwasher...............................6

113 Bushing....................................................................................1

114 Clutch Housing ........................................................................1

115 Clutch Housing To Case Stud...................................................4

116 P.T. O. Cover Plate Screw.........................................................6

117 P.T. O. Cover Plate....................................................................1

118 P.T. O. Cover Plate Gasket........................................................1

119 Magnetic Drain Plug ................................................................1

120 Filler Plug.................................................................................1

***- Not used on all models AR - As Required

CLARK

CL550-SERIES CONTROL PARTS GROUP

ITEM Description QTY

1 Gear Shift Lever Dust Cover.....................................................1

2 Gear Shift Lever Pivot Pin........................................................2

3 Control Top ..............................................................................1

4 Gear Shift Lever.......................................................................1

5 Gear Shift Lever Support Washer.............................................1

6 Support Spring ........................................................................1

7 Control Top or Remote Control Gasket ....................................1

8 Expansion Plug........................................................................1

9 Shift Rail Housing....................................................................1

10 1st & Reverse Rocker Lug .......................................................1

11 Shift Fork Lock Pin...................................................................4

12 1st & Reverse Rocker Arm ......................................................1

13 4th & 5th Shift Fork.................................................................1

14 2nd & 3rd Shift Fork ................................................................1

15 Mesh Lock Ball ........................................................................1

16 1st & Reverse Mesh Lock Spring.............................................1

17 1st & Reverse Shift Fork .........................................................1

18 1st & Reverse Shift Fork Rail Lock Pin ....................................1

19 1st & Reverse Shift Rail ..........................................................1

20 Shift Fork Bushing ...................................................................2

21 Shift Fork Bushing ...................................................................2

22 4th & 5th Shift Rail ..................................................................1

23 Rear Rail Support ....................................................................1

24 Rail Support Screw..................................................................6

25 Front Rail Support....................................................................1

26 2nd & 3rd Shift Rail .................................................................1

27 Inter-Lock Cross Pin ................................................................1

28 1st Gear Shift Stop Space (wide) .............................................1

29 1st & Gear Shift Lug................................................................1

30 1st & Gear Shift Stop Spacer ..................................................1

ITEM Description QTY

31 1st & Reverse Shift Rail...........................................................1

32 Mesh & Inter-Lock Ball ..........................................................10

33 Mesh Lock Spring....................................................................3

34 Back-up Switch Hole Plug Gasket............................................1

35 Back-up Switch Hole Plug........................................................1

36 1st & Reverse Latch Plunger Springer Plug.............................1

37 1st & Reverse Latch Plunger Plug Gasket................................1

38 1st & Reverse Latch Plunger Stop...........................................1

39 1st & Reverse Latch Plunger Spring.......................................1

40 1st & Reverse Latch Plunger ..................................................1

41 Control Top Screw ...................................................................4

42 Screw Lockwasher

CLARK

CL550-SERIES TRANSMISSION